Accordion Dunnage and Collapsible Dunnage Box With Accordion Dunnage

ABSTRACT

A collapsible dunnage adapted for being positioned in a box for transporting parts that includes a plurality of top-opening pockets for receiving the parts to be transported and formed of a flexible web positioned in side-by-side registration with each other and movable between an expanded use position and a collapsed storage position while being maintained in the same side-by-side registration position. Fastener elements are attached to the dunnage and adapted for fastening the dunnage to complementary fastener elements carried by a box in which the dunnage is adapted to be positioned for use and storage. The box is collapsible and includes features that permit convenient storage of the collapsed accordion dunnage in the collapsed box.

PRIORITY CLAIM

This application claims priority from and incorporates by reference U.S.Provisional Patent Application Ser. No. 62/833,089, filed Apr. 12, 2019and U.S. Provisional Patent Application Ser. No. 62/852,464, filed May24, 2019.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates to a new type of dunnage as described and claimedbelow, and a collapsible dunnage box in combination with the newdunnage. The dunnage as described and claimed below is referred to as“accordion” dunnage due to its unique construction that bears asuperficial similarity to the appearance of the bellows of an accordion.The box disclosed in this application in combination with the accordiondunnage is a unique design having a collapse feature and is used totransport parts to, for example, assembly lines or to other commercialand industrial locations, where the box is emptied. The term “parts” asused in this application broadly means any item or object of a size andtype suitable for being transported in dunnage in a box.

The ability of the box to be collapsed permits a large number of emptyboxes to be returned to a remote location for cleaning and/or refillingin a much smaller volume than if the boxes remained in the erectcondition. In many instances these boxes contain “dunnage.” Dunnage isgenerally defined as packing material such as boards, blocks, planks,metal or plastic bracing or other internal structures used in supportingand securing parts positioned in the box during shipment and storage.The increasing use of “just in time” parts deliveries has also increasedthe use of boxes with many varied types of internal dunnage structureswhich not only protect the parts while in the box but position the partsin a predetermined orientation for ease of removal.

This application relates to dunnage constructed of a fabric or othersheet material with an “accordion” fold conformation with pockets thatare positioned in an open condition in the box during use that cradleand separate the parts in the box from each other. This position isreferred to as the “use” position. Since this dunnage is also reusablealong with the box itself, it is most efficient and cost-effective to beable to ship the box and the dunnage together back to their place oforigin.

Prior art collapsible boxes include boxes with dunnage storage in thebottom of the box. Instead of a normal shallow bottom box component, thecollapsing walls of the box are attached to a box component as thebottom. Normally, the collapsible box collapses down to a predeterminedheight. All of the volume is filled with the folded and pivotingsidewalls. There is no empty volume for the dunnage to utilize. The openusable volume that the dunnage bottom provides is a lower area volumethat remains empty when the sidewalls are folded down. Removable dunnagecan be removed from the erect box, folded up and placed in this bottomcavity, keeping the dunnage with the collapsed box.

The present invention provides a more space-efficient and time-savingmanner of collapsing the box and its associated dunnage.

SUMMARY OF THE INVENTION

In one aspect of the invention, the storage volume of the collapsing boxis positioned in the top of the box instead of in the bottom, as withthe prior art. This is a particular benefit with the accordion-typedunnage that holds parts vertically. As described above, this dunnagemay be made of fabric or other foldable web material so when empty it iscollapsible onto itself, folding flat in an accordion-like manner withlittle effort. This dunnage is mounted proximate the top of the box.

In another aspect of the invention, as the endwalls of the box arefolded upwards, the endwalls push the bottom of the accordion dunnageupwards into the storage volume in the top of the box.

In another aspect of the invention a collapsible box with an accordiondunnage includes a bottom, first and second opposing endwalls and firstand second opposed sidewalls connecting the bottom on opposing sides ofthe box. The box may also optionally include a top cover. Each of thesidewalls includes a top sidewall panel and a bottom sidewall panelattached by a bottom hinge to the bottom. The top and bottom sidewallpanels are attached together along adjacent edges by a center hinge,whereby the top and bottom sidewalls are pivotally-moveable relative toeach other and the bottom between an erect position and a collapsedposition. The dunnage set including a plurality of foldable dunnageelements positioned in the box and moveable between a use positionsuspended from near the top of the box, hanging down into the volume ofthe box when in the box is in an erect position, being progressivelyfolded into a flattened position as the box is collapsed.

In accordance with another aspect of the invention, a collapsible box isprovided that includes a bottom, a top, and first and second opposingendwalls and first and second opposed sidewalls connecting the bottomand top of the box on opposing sides of the box. Each of the sidewallsincludes a top sidewall panel attached by a top hinge to the top, abottom sidewall panel attached by a bottom hinge to the bottom. The topand bottom sidewall panels are attached together along adjacent edges bya center hinge, whereby the top and bottom sidewalls arepivotally-moveable relative to each other and the top and bottom betweenan erect position and a collapsed position. A collar is positioned atopthe first and second opposing sidewalls and the first and secondopposing endwalls to provide a raised wall that remains erect withperpendicular walls that form a storage volume when the first and secondopposing sidewalls and the first and second opposing endwalls arecollapsed in a horizontal position.

In accordance with another aspect of the invention, a collapsibledunnage adapted for being positioned in a box for transporting parts isprovided, and includes a plurality of top-opening pockets for receivingthe parts to be transported and formed of a flexible web positioned inside-by-side registration with each other and movable between anexpanded use position and a collapsed storage position while beingmaintained in the same side-by-side registration position. Fastenerelements are attached to the dunnage and adapted for fastening thedunnage to complementary fastener elements carried by a box in which thedunnage is adapted to be positioned for use and storage.

In accordance with another aspect of the invention, the flexible web isa fabric.

In accordance with another aspect of the invention, the flexible web isselected from the group of webs consisting of fabric, film, plastic andnetting.

In accordance with another aspect of the invention, the fastenerelements are touch fastener elements adapted to fasten to complementarytouch fastener elements carried by the box.

In accordance with another aspect of the invention, the fastenerelements of the dunnage are one or the other of hooks and loops and thefastener elements of the box are complementary to the one or the otherof the hooks and loops of the dunnage.

In accordance with another aspect of the invention, the pockets includeflexible first and second sidewalls and flexible first and secondendwalls positioned between and joined to the first and secondsidewalls, the first and second sidewalls and first and second end wallsconfigured to provide one or more generally rectangularly-shaped pocketswith a volume in the use position that are adapted to collapse whenempty in an accordion-like manner.

In accordance with another aspect of the invention, a collapsible boxwith dunnage is provided that includes a bottom and first and secondopposing endwalls mounted for pivotal movement relative to the bottom.First and second opposed sidewalls connect the bottom of the box onopposing sides of the box, each of the sidewalls including a topsidewall panel and a bottom sidewall panel attached by a bottom hinge tothe bottom. The top and bottom sidewall panels are attached togetheralong adjacent edges by a center hinge, whereby the top and bottomsidewalls are pivotally-moveable relative to each other and the bottombetween an erect use position and a collapsed storage position. A collaris positioned atop the first and second opposing sidewalls and the firstand second opposing endwalls to provide a raised wall that remains erectwith perpendicular walls that form a storage volume when the first andsecond opposing sidewalls and the first and second opposing endwalls arecollapsed in a horizontal position. A collapsible dunnage is adapted forbeing positioned in the box for transporting parts, and includes aplurality of top-opening pockets for receiving the parts to betransported and formed of a flexible web positioned in side-by-sideregistration with each other and movable between an expanded useposition and a collapsed storage position while being maintained in thesame side-by-side registration position. Fastener elements are attachedto the dunnage and adapted for fastening the dunnage to complementaryfastener elements carried by a box in which the dunnage is adapted to bepositioned for use and storage.

In accordance with another aspect of the invention, the endwalls arepivotally-mounted to opposing ends of a top of the box and are adaptedto move between a position perpendicular to the top of the box in theerect use position and a position parallel to the top of the box in thecollapsed storage position.

In accordance with another aspect of the invention, a collapsible boxwith dunnage is provided that includes a bottom, top and first andsecond opposing endwalls and first and second opposed sidewallsconnecting the bottom and top of the box on opposing sides of the box.Each of the sidewalls include a top sidewall panel attached by a tophinge to the top and a bottom sidewall panel attached by a bottom hingeto the bottom. The top and bottom sidewall panels are attached togetheralong adjacent edges by a center hinge whereby the top and bottomsidewalls are pivotally-moveable relative to each other and the top andbottom between an erect position and a collapsed position. A collar ispositioned atop the first and second opposing sidewalls and the firstand second opposing endwalls to provide a raised wall that remains erectwith perpendicular walls that form a storage volume when the first andsecond opposing sidewalls and the first and second opposing endwalls arecollapsed in a horizontal position. An accordion dunnage includes aplurality pockets supported in the collar for extending into the box inan erect use position adapted for holding parts for shipment andstorage, and collapsible with the sidewalls and endwalls for storage inthe volume defined by the collar when the box is in a collapsedposition.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred and exemplary embodiments of the invention are furtherexplained with reference to the drawings, in which:

FIGS. 1-6, inclusive, are views of a prior art collapsible box;

FIG. 7 is a perspective view of a collapsible box according to anembodiment of the invention that places the “storage volume” of thecollapsed box at the top of the box instead of at the bottom;

FIGS. 8-12 are cross-sectional views of the box according to FIG. 7 inprogressive states of collapse into its storage position;

FIG. 13 is a perspective view of the box of FIG. 7 without dunnage;

FIG. 14 is a perspective view of an accordion dunnage in an open useconfiguration;

FIG. 15 is a top plan view of the accordion dunnage of FIG. 14; and

FIG. 16 is a perspective view of the accordion dunnage of FIG. 14 in aflattened, closed storage position;

FIG. 17 is a perspective view of the box of FIG. 13 in a use positionwith a closed lid;

FIG. 18 is a perspective view of the box of FIG. 13 in a deployedposition with the accordion dunnage in a use position;

FIG. 19 is a perspective view of the box of FIG. 13 in a deployedposition with the accordion dunnage in a partial use position;

FIG. 20 is a perspective view of the box of FIG. 13 moving from the useposition to the collapsed position and with accordion dunnage shown in acollapsed storage position.

FIG. 21 is a perspective view of the box of FIG. 13 in a collapsedposition and with accordion dunnage shown in a collapsed storageposition; and

FIG. 22 is a perspective view of the box of FIG. 13 as it is beingtransitioned from the storage position with the accordion dunnage shownin a partially collapsed storage position moving to a use position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE Prior Art

Referring now specifically to the drawings, a collapsible box “CB”according to a prior art collapsible box is shown in FIGS. 1-6. Thecollapsible box “CB” of FIG. 1 is shown in a fully erect, use position.The collapsing walls are attached at the bottom. The height “B” showsthe open usable volume that the dunnage bottom provides. FIG. 2 shows anendwall being folded into the volume of the collapsible box CB″ as partof the collapse process. FIG. 3 shows the box “CB” fully collapsed, withthe height “A” representing the volume that is filled with the foldedand pivoting sidewalls, with no empty volume. In FIG. 4 the collapsedbox “CB” is opened by first folding away the interlocking covers. Thelower volume is shown remaining empty when the sidewalls are foldeddown. According to FIGS. 5 and 6, removable dunnage pockets can beremoved from the erect box “CB”, folded up and placed in the bottom ofthe collapsed box “CB”, keeping the dunnage pockets with the collapsedbox “CB”.

Dunnage Box

A collapsible dunnage box 10 with which the accordion dunnage of theinvention is used is shown in FIGS. 7-13 and 17-22. As best shown inFIG. 7, the box 10 includes a base 12 to which are mounted opposed firstand second base endwalls 14, 16 and first and second base sidewalls 18,20. The base endwalls 14, 16 are mounted for pivoting movement on baseendwall hinges 14A, 16A. The base sidewalls 18, 20 are formed by twobase sidewall panels 18A, 18B and 20A, 20B, respectively that are joinedalong an adjoining common hinge line by respective base sidewall hinges18C, 20C.

Top endwalls 22, 24 are mounted to the top edge of the base endwalls 14,16, respectively, and top sidewalls 26, 28 are pivotally mounted to thetop edge of the base sidewall panels 18A, 20A, respectively. The topendwalls 22, 24 and top sidewalls 26, 28 collectively define a collar30. The collar 30 includes a pair of opposed lifting recesses 31.

The box 10 is usable with various types of dunnage. Prior art dunnageincludes individual pockets positioned in the box 10 and suspended fromdunnage hangers by fastening members, for example, hooks, attached tothe top of the dunnage pockets. This prior art dunnage is preferablyconstructed of a crushable, reusable web material, for example, cloth,plastic, film or similar material, capable of being crushed andcompressed into a randomly-defined shape and then decompressed intotheir original shape for reuse by being suspended from the dunnagehangers by the hooks or other fastening members.

In contrast to the collapsible box “CB” of FIGS. 1-6, the storage volumefor the dunnage is formed in the top of the box 10 in the collar 30. Ineffect, the storage volume is defined by the collar 30 that extendsaround the top of the box 10 as shown even when the box 10 is completelycollapsed. This is particularly useful with dunnage of the type that isformed of hanging dunnage elements, for example, the dunnage pocketsdescribed above, or the novel accordion dunnage described below thathold parts vertically within their folds.

Referring now to FIGS. 8-12, the box 10 has been verticallycross-sectioned to more clearly reveal the interior of the box 10 andthe interrelationship between the action of the base endwalls 14, 16 andthe base sidewalls 18, 20.

FIG. 8 shows the base endwalls 14, 16 and the base sidewalls 18, 20 flatand fully erect, in the deployed “use” position capable of storing andshipping parts in the dunnage, not shown.

FIG. 9 shows the beginning of the box 10 collapsing process, with thebase endwalls 14, 16 being pushed inwardly and upwardly into the volumeof the box 10 and towards each other into a storage position.

In FIG. 10, the base endwalls 14, 16 are fully pushed inwardly and upinto the storage position perpendicular to their use position, while thebase sidewalls 18, 20 remain vertical and fully erect, as in FIGS. 8 and9.

In FIG. 11, the base endwalls 14, 16 are fully pushed up into thestorage position, with the base sidewalls 18, 20 beginning to hingeinwardly into the volume of the box 10 along their common hinges 18C,20C.

In FIG. 12 the box 10 is fully collapsed into a storage position, withthe base endwalls 14, 16 now forming the base of a dunnage pocket 32storage volume. Note that the fully hinged, stowed base sidewalls 18, 20reside in the box 10 directly beneath the stowed base endwalls 14, 16.The collar 30 has now descended onto the top of the base 12 and definesa volume sufficient for the dunnage to be folded and positioned in thatvolume for storage and shipment back to, for example, a parts supplierwhere the box 10 will be re-erected by reversing the process shown anddescribed in FIGS. 8-12. FIG. 13 shows a fully erected box withoutdunnage pockets for clarity.

Accordion Dunnage

Referring now to FIGS. 14-16, a novel dunnage, referred to as“accordion” dunnage is shown. The accordion dunnage 50, two sets ofwhich are shown, includes a plurality of top opening pockets, 52, 54, 56into which parts can be placed for shipment and storage. The threepockets 52, 54, 56 are constructed of sidewalls 58, 60, 62, 64 andendwalls 66, 68, 70, 72, 74 and 76. The sidewalls 58, 60, 62, 64 areconstructed in registration with each other, as shown. A bottom panel78, which may be a single or separate panels for each pocket 52, 54, 56,encloses the bottom of the pockets 52, 54, 56. Other embodiments of theaccordion dunnage may include any suitable number of pockets including asingle pocket.

The accordion dunnage 50 is preferably fabricated of a flexible web, forexample, webs of fabric, film, plastic or netting or a combination ofthese webs. The specific web selected will depend on a number of factorsthat will widely vary, including the weight, size and shape of the partsto be placed in the pockets 52, 54, 56, requirements for flameretardancy, wear, chemical resistence and the like.

Due to its flexibility and construction, the accordion dunnage 50 ismovable between an expanded use position shown in FIGS. 14 and 15, and acollapsed storage position shown in FIG. 16, while being maintained inthe same side-by-side registration configuration. The construction ofthe accordion dunnage 50 not only resembles an accordion bellows withits pleats, but functions in a similar manner, expanding and flatteningbetween the use and storage positions.

The components of the accordion dunnage 50 may be joined by any suitablemeans, including stitching, seaming, such as overedge seaming, gluing,stapling, sonic welding or any other suitable means depending on thematerial from which the sidewalls 58, 60, 62, 64 and endwalls 66, 68,70, 72, 74 and 76 are constructed.

The accordion dunnage 50 can be suspended in the box 10 in any suitablemanner. One suitable manner is the use of touch fasteners, for examplehook and loop elements 80 that cooperate with complementary hook andloop elements attached to the interior of the box 10 near the top. Touchfasteners or other attachment elements may be placed strategically onthe accordion dunnage 50 itself so that when a plurality of accordiondunnage 50 sets are in the use position in the box 10, adjacentattachment elements provide mutual support to the accordion dunnage 50.

Referring now to FIGS. 17-23, FIG. 17 shows a dunnage box 10 in itsdeployed use position as it would appear with the accordion dunnage 50sets positioned in the box 10 and loaded with parts, with the lid 40,42closed for shipment and storage.

As shown in FIGS. 18 and 19, with the lid 40, 42 removed for clarity,the accordion dunnage 50 is shown in position in the box 10. In FIG. 18,two sets of the accordion dunnage 50 are shown fully expanded and in theuse position. FIG. 19 shows one set of the accordion dunnage 50collapsed in preparation for the box 10 being collapsed, with the otherset of accordion dunnage 50 still in its expanded use position.

In FIG. 20 the accordion dunnage 50 has been collapsed into storageposition resting on the inwardly folded endwalls 14, 16 and the box 10is beginning its movement into its collapsed storage position, shown inFIG. 21.

FIG. 22 shows the box 10 having been expanded into its use position withthe endwalls 14, 16 in the process of being folded outwardly anddownwardly into the use position. As this occurs, the accordion dunnage50 is allowed to fold back down into the expanded box 10 and into itsuse position, as shown in FIG. 18.

The accordion dunnage 50 is therefore conveniently stored in the topportion of the box 10 in its collapsed position and thus can remain withthe box 10 when being shipped in its collapsed position back to afacility where it is expanded into its use position, the accordiondunnage deployed into its use position and refilled with parts forshipment to, for example, an assembly line for again being emptied.

An accordion dunnage and collapsible dunnage box with accordion dunnageaccording to the invention has been described with reference to specificembodiments and examples. Various details of the invention maybe changedwithout departing from the scope of the invention.

Furthermore, the foregoing description of the preferred embodiments ofthe invention and best mode for practicing the invention are providedfor the purpose of illustration only and not for the purpose oflimitation, the invention being defined by the claims.

I claim:
 1. A collapsible dunnage adapted for being positioned in a boxfor transporting parts, comprising: (a) one or more top-opening pocketsfor receiving the parts to be transported and formed of a flexible webspositioned in side-by-side registration with each other and movablebetween an expanded use position and a collapsed storage position whilebeing maintained in the same side-by-side registration position; (b)fastener elements attached to the dunnage and adapted for fastening thedunnage to complementary fastener elements carried by the box in whichthe dunnage is adapted to be positioned for use and storage.
 2. Acollapsible dunnage according to claim 1, wherein the flexible web is afabric.
 3. A collapsible dunnage according to claim 1, wherein theflexible web is selected from the group of webs consisting of fabric,film, plastic and netting.
 4. A collapsible dunnage according to claim1, wherein the fastener elements are touch fastener elements adapted tofasten to complementary touch fastener elements carried by the box.
 5. Acollapsible dunnage according to claim 1, wherein the fastener elementsof the dunnage are one or the other of hooks and loops and the fastenerelements of the box are complementary of the one or the other of thehooks and loops of the dunnage.
 6. A collapsible dunnage according toclaim 1, and including a plurality of pockets having flexible first andsecond sidewalls and flexible first and second endwalls positionedbetween and joined to the first and second sidewalls, the first andsecond sidewalls and first and second endwall configured to provide agenerally rectangularly-shaped pocket volume in the use position thatare adapted to collapse when empty in an accordion-like manner.
 7. Acollapsible box with dunnage , comprising: (a) a bottom; (b) and firstand second opposing endwalls mounted for pivotal movement relative tothe bottom; (c) first and second opposed sidewalls connecting the bottomof the box on opposing sides of the box, each of the sidewallscomprising; (I) a top sidewall panel; (ii) a bottom sidewall panelattached by a bottom hinge to the bottom; (iii) the top and bottomsidewall panels attached together along adjacent edges by a centerhinge, whereby the top and bottom sidewalls are pivotally-moveablerelative to each other and the bottom between an erect position and acollapsed storage position; (iv) a collar positioned atop the first andsecond opposing sidewalls and the first and second opposing endwalls toprovide a raised wall that remains erect with perpendicular walls thatform a storage volume when the first and second opposing sidewalls andthe first and second opposing endwalls are collapsed in a horizontalposition; and (v) a collapsible dunnage adapted for being positioned inthe box for transporting parts, comprising: (a) a plurality oftop-opening pockets for receiving the parts to be transported and formedof flexible webs positioned in side-by-side registration with each otherand movable between an expanded use position and a collapsed storageposition while being maintained in the same side-by-side registrationposition; and (b) fastener elements attached to the dunnage and adaptedfor fastening the dunnage to complementary fastener elements carried bya box in which the dunnage is adapted to be positioned for use andstorage.
 8. A collapsible box according to claim 7, wherein the endwallsare pivotally-mounted to opposing ends of a top of the box and areadapted to move between a position perpendicular to the top in the erectposition and a position parallel to the top in the collapsed storageposition.
 9. A collapsible box with dunnage, comprising: (a) a bottom,top and first and second opposing endwalls; (b) first and second opposedsidewalls connecting the bottom and top of the box on opposing sides ofthe box, each of the sidewalls comprising; (I) a top sidewall panelattached by a top hinge to the top; (ii) a bottom sidewall panelattached by a bottom hinge to the bottom; (iii) the top and bottomsidewall panels attached together along adjacent edges by a centerhinge, whereby the top and bottom sidewalls are pivotally-moveablerelative to each other and the top and bottom between an erect positionand a collapsed position; (iv) a collar positioned atop the first andsecond opposing sidewalls and the first and second opposing endwalls toprovide a raised wall that remains erect with perpendicular walls thatform a storage volume when the first and second opposing sidewalls andthe first and second opposing endwalls are collapsed in a horizontalposition; and (v) a dunnage set comprising a plurality of dunnageelements having pockets supported in the collar for extending into thebox in an erect use position and adapted for holding parts for shipmentand storage, and collapsible with the sidewalls and endwalls for storagein the volume defined by the collar when the box is in a collapsedstorage position.
 10. A collapsible dunnage according to claim 9,wherein the flexible web is a fabric.
 11. A collapsible dunnageaccording to claim 9, wherein the flexible web is selected from thegroup of webs consisting of fabric, film and netting.
 12. A collapsibledunnage according to claim 9, wherein the fastener elements are touchfastener elements adapted to fasten to complementary touch fastenerelements carried by the box.
 13. A collapsible dunnage according toclaim 9, wherein the fastener elements of the dunnage are one or theother of hooks and loops and the fastener elements of the box arecomplementary to the one or the other of the hooks and loops of thedunnage.
 14. A collapsible dunnage according to claim 9, wherein thepockets include flexible first and second sidewalls and flexible firstand second endwalls positioned between and joined to the first andsecond sidewalls, the first and second sidewalls and first and secondendwall configured to provide a generally rectangularly-shaped pocketvolume in the use position that are adapted to collapse when empty in anaccordion-like manner.